Installation Manual
PaveDrain® Installation Manual
Table of Contents
Section 1:
Base Preparation (pages 3 – 6)
Section 2:
Hand-Placement of individual PaveDrain
Blocks (pages 8 – 11)
Section 3:
Mattress Installation (pages 12 – 15)
Section 4:
Edge Restraints (pages 16 – 19)
Section 5:
PaveDrain End Block & End Cap
(pages 19 - 20)
Section 6:
Finishing the PaveDrain System
(pages 20 – 21)
Section 1
Base Preparation
Open Graded Base & Bedding Course Aggregate: If more than 6” of base stone is
required, only the top 4-6” shall be AASHTO #57 stone (3/4” – 1” clean, angular, with no fines), which
is used as a leveling course directly beneath the blocks (SEE Fig. 1). Additional stone depth should
consist of either AASHTO #2 or #3 stone, or as shown in drawings.
Edge Restraint: Defining the edges of the PaveDrain system is important (SEE examples on
page 16). Concrete curbing is the most commonly used material. However, using other materials
such as plastic strip edging (commonly used in typical pavers ) is not advisable.
Separation Fabric: A high strength woven monofilament or multi-filament geotextile is highly
recommended to be installed as a base reinforcement and separation layer between the aggregate
storage bedding layer (depth to be determined) an the native sub-grade. Please check with your local
PaveDrain representative to determine the appropriate geosynthetic required. The geosynthetic is a
key component of the PaveDrain system. Negating its use could be detrimental to the function,
performance and life cycle of the PaveDrain system. The “vertical walls” of your prepared area should
also be lined with an appropriate geosynthetic to prevent soil and aggregate migration (SEE Fig. 2).
Fig. 1
Fig. 2
LAYOUT & PREPARATION
If individual units are to be installed they will arrive wrapped on pallets. Pallets will weigh
approximately 3,900 lbs. or less. If the PaveDrain system is installed in mattress form, a mat layout
will be provided by PaveDrain, LLC or its representatives. Mat weights and sizes will be determined in
advance of shipment. Each mat will be pre-fabricated at the manufacturing facility and delivered to
the site ready to be installed.
NOTE: Before digging, always call your local utility companies to locate any underground
utilities.
PREPARE SUBGRADE SOILS
For best results, the finished subgrade should be flat, smooth and stable. A California Bearing Ratio
(CBR) should be established well in advance of the installation. The appropriate geosynthetic is critical
and should prevent rutting. If the subgrade appears weak or damp following the installation of the
appropriate Geosynthetic contact a professional geotechnical engineer or local PaveDrain
representative for further assistance.
Fig. 3
Fig. 4
PREPARATION OF OPEN GRADED BASE
The depth of stone should be determined well in advance of the installation of the PaveDrain system
by the engineer of record based on the CBR and storm water storage requirements.
Open graded base materials must be free of fines. Take care not to track soil onto the geosynthetic or
allow sediment to wash into the excavation during construction.
AASHTO #57 stone is recommended as the bedding layer of stone. Place the stone on the
appropriate geosynthetic in 6-8” lifts and compact with a vibratory roller. The use of a vibratory plate
compactor in both directions is best for final compaction of the bedding layer of AASHTO #57 stone
that will be in direct contact with the bottom of the PaveDrain units unless the optional geogrid is used
(See below). There should be no visible movement of the material once compacted and the base
should be smooth when completed.
GEOGRID
(Recommended)
REMEMBER: Subgrade preparation is CRITICAL! The PaveDrain system will mirror any grade
changes or discrepancies made with the subgrade.
Fig. 5
If it is determined by the engineer of record that a rock depth in excess of 12” is required, then the
cross-section below should be followed.
GEOGRID
(Recommended)
Approved
geotextile or
geogrid
CRUCIAL TOOLS
Professional survey equipment is always recommended; other suggested materials are pipe lasers (if
available), marking paint, tape measure, chalk line, block markers/crayons, string line, survey stakes,
rubber mallets, 4’-5’ pry bars, 4 ½” angle grinder with concrete cutting blade, masonry saw (wet/dry)
with diamond cutting blade, spade and flat shovel, hard-tooth garden rake, Geosynthetic, “peanut” or
double roller and plate compactor.
**BUMP BAR** – For Mattress Installation
See Step #5 in the Mattress Installation section below for further details and Fig. 21 for a photo of the
bar. Made from 5” x 5” angle iron that is roughly 7-8’ in length.
Section 2
Hand-Placement of PaveDrain Blocks
Hand placing of individual PaveDrain units is an option when your project poses certain problems,
such as low over-head power/telephone lines, tight areas between buildings and any other area you
cannot operate a crane or excavator to install mats. This method of installation typically requires (1)
foreman (with minimal experience and/or minimal training of the PaveDrain system) and (3) general
laborers. The (4) man crew will be able to install roughly 1,500 SF per day. The amount of SF they
install will increase as their experience grows. The foreman will be able to operate any of the
necessary equipment (i.e. forklift, bobcat or mini-excavator) while directing the laborers. It’s also
recommended to choose this option of installation when your project is 5,000 SF or smaller.
Step #1:
If existing hardscapes are to remain (i.e. asphalt
or concrete) the prepared area
needs to be 3” (three) inches larger than the area to receive the individual units. In
some applications a concrete collar can be poured before the units are installed (SEE
Fig. 6 & 7).
Fig. 6
Fig. 7
Step #2:
Base preparation is CRITICAL!!!
Undulations and grade changes in the rock base will be reflected in the PaveDrain
system. A plate compactor may be the best way to level and flatten the base rock
before and during installation (See Fig. 5). A well prepared rock base is shown in
(Fig. 9).
Fig. 8
Fig. 9
Step #3:
STARTING POINT….It is beneficial to take the entire area into consideration and lay
your first unit in one of two places; the middle or in one corner. String lines will help
facilitate your placement. If you decide to place your first unit in the middle you must
mark that unit in the middle with a “+”. Then use your string lines to find the exact
middle of your open area. Place the unit with the “+” under the intersection of your
string lines and you are ready to begin (SEE Fig. 11). If you start in one corner, you
want to use your string line to make an exact 90° corner where you will lay your first
unit (SEE Fig. 10).
Fig. 10
Fig. 11
Step #4:
Fig. 12
Keep the units tight during installation and follow the string lines. Rubber mallets may
help you “seat” the units after they are placed (SEE Fig. 12 & 13).
Fig. 13
NOTE:
Foot traffic should be kept to a minimum on the rock. If the rock is
compacted correctly, little movement should be apparent once stepped
on. Use the plate compactor to fix any major damage.
Step #5:
The individual PaveDrain units can be cut or tailored to accommodate a variety of
different shaped working areas or obstacles within the working area. Using a concrete
block masonry saw with a diamond tipped blade will allow you to custom fit your site
(SEE Fig. 14 & 15)!
Fig. 14
Fig. 15
Section 3
Mattress Installation
Step #1:
If existing hardscapes are to remain (I.E. asphalt or concrete) the prepared area needs
to be 1’ (one) foot larger than the mats. Mats to be installed are 16.3’. Prepared area is
17.4’ (SEE Fig. 16).
Fig. 16
Step #2:
Base preparation is CRITICAL!!!
Undulations and grade changes in the rock base will be reflected in the PaveDrain
system. A plate compactor may be the best way to level and flatten the base rock before
and during installation (SEE Fig. 17, 18 & 11) “Base Preparation” Section.
Fig. 17
Fig. 18
Step #3:
DO NOT UNDERESTIMATE the sag in the mat. The longer the mat the more the mat
will sag and the higher you will need to pick the mat in order to get it off of the truck
(SEE Fig. 19).
Fig. 19
PaveDrain® Mats were 7.14’ x
32.2’ and weighed 11,500 lbs.
The Spreader bar weighed an
additional 3,500 lbs.
NOTE:
PaveDrain’s Mat Installation Spreader Bar is available for rent. It will arrive
(ready to use) on the first truckload of mats. PaveDrain, LLC can also supply
drawings to anyone who would like to fabricate their own spreader bar.
Step #4:
“Zippering” the mats into place can be facilitated with pry bars (SEE Fig. 20).
Fig. 20
Step #5:
Fig. 21
“Bumping” the mats to create a secure fit is highly recommended. The fabrication of a
“bump bar” (SEE Fig. 21) will help close any unwanted gaps that are larger than the
required ¼” established by the unit spacer. Gaps within the mattress area can be
bumped from all sides to achieve the desired tightness (SEE Fig. 22 and 23). The bump
bar is made for 5” x 5” angle iron and is roughly 8’ long. Adding handles (SEE Fig. 21)
will help with moving the bar from mat to mat.
Fig. 22
The BUMP BAR can be PULLED with the bucket
to help adjust the gap.
Fig. 23
The BUMP BAR can be PUSHED with the bucket
to help adjust the gap.
Step #6:
If Submittal pack requires the use of PaveDrain Lock Block™ and/or Lock Block rows you
will need a 4 ½” dia. angle grinder with a concrete cutting blade; only if units are not
already notched (SEE Fig. 24 & 25).
Fig. 25
Fig. 24
Step #7:
Once the mats have been zippered together, if there are any differential heights between
the mats, they can be vibrated into place by putting a non-woven geotextile on top of the
blocks and then running a plate compactor over the zippered seam (SEE Fig. 26). A static
roller can also be utilized (SEE Fig. 29 & 30).
Fig. 26
Step #8:
The PaveDrain mats can be tailored to accommodate a variety of obstacles within the
working area such as; water meter openings, man-holes, existing curb drains, light posts,
sign posts and/or existing concrete structures. PaveDrain® mats can be tailored by
removing individual units within the mat (before the mat is installed OR after the mat is
installed) (SEE Fig. 27 & 28 on the next page).
Fig. 27
Fig. 28
Section 4
Edge Restraints
Edge restraint is used to delineate and confine a PaveDrain system and is highly
recommended whenever vehicular loads are present. There are many acceptable options for edge
restraint with the PaveDrain System. The detail below and on the following page show the most
common method utilizing a poured-in-place concrete flush curb. If you wish to consider other
alternates please contact your local sales representative for support.
GEOGRID
(Recommended)
GEOGRID
(Recommended)
The Two Stage Curb detail below is an edge restraint solution that can be used when
the PaveDrain System terminates on a curve or radius. The Two Stage Curb detail eliminates the need
for field cutting of the PaveDrain blocks to match the required curve or radius .
GEOGRID
(Recommended)
1. Minimal cutting of the
PaveDrain blocks.
2. Compacted rock is
brought to proper
height.
3. Exposed rebar is for
securing poured curb
after the block are
installed.
Curb is poured ON TOP of the PaveDrain.
Completed Two Stage Curbs
Section 5
PaveDrain End Block & End Cap
The PaveDrain End Block is designed to give a smooth transition between the
PaveDrain system and existing surfaces. Installation of the End Block can be done in conjunction with
Mattress Installations or Hand-Placement of PaveDrain system.
Conventional materials, such as rock,
asphalt or concrete, are easily placed
directly between the PaveDrain® End Block
and the existing structure.
The PaveDrain End Cap is a patented expansion joint made from 100% recycled rubber tires
and keeps material and debris from entering the arched storage chamber of the blocks. It is
manufactured in 4’ sections and is made to fit the shape of the PaveDrain units. Installation of the
End Caps can be done in conjunction with Mattress Installation or Hand-Placement of PaveDrain®.
Conventional materials, such as
asphalt, are easily placed directly
against the PaveDrain® End Cap.
PaveDrain Units were Hand-Placed
within an existing concrete parking
lot. The End Caps act as an
expansion joint in this application.
Before
After
Section 6
Finishing the PaveDrain System
As always, the joints within the PaveDrain system are designed to be left open. Placing
sand or small rock chips within the open joints is not recommended. Following the installation of the
PaveDrain system slight unevenness between the individual blocks may be evident. To resolve this, a
static (non-vibrating) double-drum roller or paver roller may be ran over the top of the PaveDrain
system (SEE Fig. 29 & 30 on the next page).
Fig. 29
Fig. 30